Rear Brake Cluster Assembly Installation; Wheel Cylinder Replacement; Front Wheel Cylinder Removal - Pioneer 1200 Maintenance Service Manual

MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS
WIRE TIE
FLEX BRAKE
HOSE
Figure 6-18 Rear Brake Hose With Plastic Bag

REAR BRAKE CLUSTER ASSEMBLY INSTALLATION

1. Install the back plate to the axle tube flange with four new Torx-head bolts (16), washers (17), and lock
nuts (18). Tighten all four bolts to 76 in-lb (8.6 N·m) (Figure 6-19, Page 6-21). See following CAUTION.
∆
CAUTION
• Do not substitute hex-head bolts for Torx-head bolts. Hex-head bolts can interfere with the
proper operation of the brake shoe adjusters.
2. Connect the brake hose fitting to the wheel cylinder and tighten the flare nut fitting to 11 ft-lb (14.9 N·m).
3. Install the park brake cable into the cable support bracket by sliding the coiled spring wire through the
slot in the bracket and feed the clevis end to the park brake lever (Figure 6-16, Page 6-18).
4. Install the park brake cable clip (1), clevis pin (3) and hair spring cotter pin (2).
5. Install rear brake shoes. See Rear Brake Shoe Installation on page 6-12.
6. Install rear wheel brake drum. See Rear Wheel Brake Drum Installation on page 6-16.
7. Repeat steps 1 through 6 for the opposite rear wheel if necessary.
8. Bleed the rear wheel brakes. See Bleeding the Hydraulic Brake System on page 6-31.
9. Perform all of the brake system inspections. See Brake System Inspection on page 6-1.

WHEEL CYLINDER REPLACEMENT

See General Warning, Section 1, Page 1-1.
∆
WARNING
• To perform this procedure, the hydraulic system must be opened. As a result, the brakes must
be bled after the correct reinstallation of the brake components. Failure to bleed the brakes
could result in decreased braking performance due to air being trapped in the hydraulic
system. Use only DOT 5 brake fluid. See Bleeding the Hydraulic Brake System on page 6-31.

FRONT WHEEL CYLINDER REMOVAL

1. Remove front brake drum. See Front Wheel Brake Drum Removal on page 6-6.
2. Remove front brake shoes. See Front Brake Shoe Removal on page 6-8.
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
PLASTIC
BAG
Wheel Cylinder Replacement
Page 6-19
6